3d Systems, Inc.

Other

Wayne A Vinson

Dennis R Smalley

Charles W Hull

Stuart T Spence

Paul F Jacobs

Charles W Lewis

Raymond S Freed

Mark Anthony Lewis

Kris A Schmidt

Frank F Little

Robert T Pitlak

Yehoram Uziel

Wolfgang Schwarzinger

Harry L Tarnoff

Borzo Modrek

Thomas J Vorgitch

Joseph W Allison

Richard A Harlow

Thomas P Chen

Paul H Marygold

Grady O Floyd

Raymond A Bradford

An improved stereolithography system for generating a three-dimensional object by creating a cross-sectional pattern of the object to formed at a selected surface of a fluid medium capable of altering its physical state in response to appropriate synergistic stimulation by impinging radiation, particle bombardment or chemical reaction, information defining the object being structurally specified to reduce curl, stress and distortion in the ultimately formed object, the successive adjacent laminae, representing corresponding successive adjacent cross-sections of the object, being automatically formed and integrated together to provide a step-wise laminar buildup of the desired object, whereby a three-dimensional object is formed and drawn from a substantially planar surface of the fluid medium during the forming process. A stereolithographic distortion known as curl is defined, and several techniques to eliminate or reduce curl are described, including dashed line, bent line, secondary structure, rivets, and multi-pass techniques. In addition, a quantitative measurement of curl known as the curl factor, and a test part known as a quarter cylinder are described, which together can be used to measure the effectiveness of the above techniques in reducing curl.

Stereolithographic curl reduction

The instant invention is directed to related methods of producing a three-dimensional object by dispensing sheets of a material, capable of physical transformation upon exposure to synergistic stimulation, onto a substantially flat working surface of a previous cross-section. In one preferred embodiment, sheets of a photoresist are employed which change solubility upon exposure to electromagnetic radiation. In other preferred embodiments, non-photoreactive sheets are employed, which ablate upon exposure to infrared radiation.

Method of building three dimensional objects with sheets

A stereolithography system employing a more powerful laser and faster dynamic mirrors to speed up part building without sacrificing accuracy is described, especially large or complex parts. A controllable shutter is placed in the beam path of the laser to selectably block the passage of the beam and prevent unwanted solidification. A suitable servo controlled feedback loop is provided to accurately position the mirrors at the higher velocity. Also described is a means to reduce data flow by distributing tasks in a multiple processor environment, and to improve user interaction by the use of a spreadsheet model. These also improve the speed of part building, especially for large or complex parts.

Rapid and accurate production of stereolithographic parts

A method and apparatus for eliminating or substantially reducing curling effects in stereolithographically formed objects. Synergistic stimulation is applied to a curable material to form a three dimensional object through the build up of successive layers. Curling between successive layers is eliminated or substantially reduced by curing a balancing layer in relation to a balanced layer such that reverse curl of the balanced layer caused by the balancing layer offsets or negates normal curl of the balanced layer caused by the balancing layer.

Method and apparatus for stereolithographic curl balancing

Systems for and methods of generating three-dimensional objects from a medium capable of selective physical transformation upon exposure to synergistic stimulation, whereby sheets of medium corresponding to cross-sectional layers of the three-dimensional object are dispensed from a source, the dispensed sheets then being selectively exposed to synergistic stimulation thereby forming a layer of the three-dimensional object, the areas not exposed to synergistic stimulation being removed, and whereby successive sheets corresponding to successive cross-sectional layers are dispensed and selectively exposed to synergistic stimulation and integrated together with preceding layers to provide substantially a layer by layer buildup of the three-dimensional object, thereby forming the three-dimensional object.

Apparatus for building three-dimensional objects with sheets

Rapid and accurate production of stereolighographic parts

An improved sterolithography system for generating a three-dimensional object from object defining information, the information defining the object being structurally specified to reduce curl, stress and distortion in the ultimately formed object is described. A stereolithographic distortion known as curl is reduced by the system, and several techniques to eliminate or reduce curl are utilized by the system, including dashed line, bent line, secondary structure, rivets, and multi-pass techniques.

Method of and apparatus for production of three-dimensional objects by

Growing community of inventors

Valencia, CA, United States of America

Wayne A Vinson